DEBURRING GAUGE FOR STATOR OF AN ELECTRIC MOTOR
A deburring gauge system that includes a gauge set, a gauge holder secured to the gauge set, and a controller. The gauge set is configured to be at least partially inserted into a slot set of a stator. Each gauge part of the gauge set includes a body having a shape that corresponds to a shape of a respective slot of the slot set. The body of each gauge part includes an abrasive portion extending along a length of the body. The controller is in communication with the gauge holder and configured to move the gauge holder in a first direction toward the stator so that the abrasive portion of the body is at least partially inserted into the respective slot and move the gauge holder in a second direction away from the stator so that the abrasive portion of the body is removed from the respective slot.
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The present disclosure relates to a deburring gauge for a stator of an electric motor.
BACKGROUNDThe statements in this section merely provide background information related to the present disclosure and may not constitute prior art.
Electric machines (e.g., electric motors and generators) may be used in a vehicle such as a fully electric vehicle or a hybrid-electric vehicle. The electric machine includes, inter alia, a stator and a rotor. The rotor is supported for rotation within a bore of the stator and includes windings or permanent magnets that interact with windings of the stator to generate rotation of the rotor when the electric machine is energized. The rotor may be supported on a driveshaft that is configured to couple with a load such as a drivetrain of the vehicle.
The stator may go through a manufacturing process in which parts of the stator are insulated by a molding process. Upon completion of the molding process, the dimension of the slots of the stator are measured to provide for the slots being within predetermined tolerance ranges. Gauges may be used to measure the dimensions of the slots. Furthermore, burrs leftover from the molding process may need to be removed from the slots of the stator. Conventionally, the burrs are removed from the slots of the stator using a manual process.
SUMMARYThis section provides a general summary of the disclosure and is not a comprehensive disclosure of its full scope or all of its features.
In one form, the present disclosure provides a deburring gauge system for a stator that includes a gauge set, a gauge holder, and a controller. The gauge set is configured to be at least partially inserted into a slot set of the stator. Each first gauge part of the gauge set includes a first body having a first cross-sectional shape that corresponds to a second cross-sectional shape of a respective first slot of the slot set. The first body of each first gauge part includes an abrasive portion extending along a length of the first body. The gauge holder is secured to the gauge set. The controller is in communication with the gauge holder and is configured to move the gauge holder in a first direction toward the stator so that the abrasive portion of the first body is at least partially inserted into the respective first slot of the slot set of the stator, and move the gauge holder in a second direction away from the stator so that the abrasive portion of the first body is removed from the respective first slot of the slot set of the stator.
In variations of the deburring gauge system of the above paragraph, which can be implemented individually or in any combination: the abrasive portion includes a series of ridges or a removable sandpaper structure; the abrasive portion includes a series of ridges and a removable sandpaper structure; each first gauge part of the gauge set includes an end extending from the first body, the end is tapered in the first direction; the controller is configured to move the gauge set in a reciprocating motion when the abrasive portion of the first body is at least partially inserted into the respective first slot of the slot set of the stator; the first body includes a non-abrasive portion extending along the length of the first body, the abrasive portion extends along the length of the first body a first distance and the non-abrasive portion extends along the length of the first body a second distance that is greater than the first distance; the first cross-sectional shape of each first gauge part of the gauge set is rectangular; the gauge set further includes second gauge parts secured to another gauge holder, each second gauge part configured to be inserted into the respective first slot of the slot set, each second gauge part includes a second body having a third cross-sectional shape that corresponds to the second cross-sectional shape of the respective first slot of the slot set; and a length of the second body of each second gauge part is greater than the length of the first body of each first gauge part.
In another form, the present disclosure provides a deburring gauge system for a stator that includes a first gauge set, a second gauge set, a first gauge holder, a second gauge holder, and a controller. The first gauge set is configured to be at least partially inserted into a slot set of the stator. Each first gauge part of the first gauge set includes a first body having a first cross-sectional shape that corresponds to a second cross-sectional shape of a respective slot of the slot set. The first body of each first gauge part includes an abrasive portion extending along a length of the first body. The second gauge set is configured to be at least partially inserted into the slot set of the stator. Each second gauge part of the second gauge set includes a second body having a third cross-sectional shape that corresponds to the second cross-sectional shape of the respective slot of the slot set. The first gauge holder is secured to the first gauge set. The second gauge holder is secured to the second gauge set. The controller is in communication with the first gauge holder and the second gauge holder. The controller configured to move the first gauge holder toward the stator so that the abrasive portion of the first body of each first gauge part is at least partially inserted into the respective slot of the slot set, move the first gauge holder away from the stator so that the abrasive portion of the first body of each first gauge part is removed from the respective slot of the slot set, move the second gauge holder toward the stator so that the second body of each second gauge part is at least partially inserted into the respective slot of the slot set, the second gauge holder being moved toward the stator after the abrasive portion of the first body of each first gauge part is removed from the respective slot of the slot set, and move the second gauge holder away from the stator so that the second body of each second gauge part is removed from the respective slot of the slot set.
In variations of the deburring gauge system of the above paragraph, which can be implemented individually or in any combination: the abrasive portion includes one or more of a series of ridges and a removable sandpaper structure; the first body of each first gauge part is inserted into a first end of the respective slot of the slot set and the second body of each second gauge part is inserted into a second end of the respective slot of the slot set that is opposite the first end; the first body of each first gauge part is inserted into an end of the respective slot of the slot set and the second body of each second gauge part is inserted into the end of the respective slot of the slot set; a length of the second body of each second gauge part is greater than the length of the first body of each first gauge part; the first body includes a non-abrasive portion extending along the length of the first body a first distance, and wherein the abrasive portion extends along the length of the first body a second distance, the first distance being greater than or equal to the second distance; each first gauge part of the first gauge set includes an end extending from the first body, the end is tapered; and the controller is configured to move the first gauge set in a reciprocating motion when the abrasive portion of the first body is at least partially inserted into the respective slot of the slot set.
In yet another form, the present disclosure provides a method for deburring and measuring a slot set of a stator, the method includes moving a first gauge holder toward the stator so that an abrasive portion of a first body of a first gauge part secured to the first gauge holder is at least partially inserted into a respective slot of the slot set, moving the first gauge holder away from the stator so that the abrasive portion of the first body of the first gauge part is removed from the respective slot of the slot set, moving a second gauge holder toward the stator so that a second body of a second gauge part secured to the second gauge holder is at least partially inserted into the respective slot of the slot set, the second gauge holder being moved toward the stator after the abrasive portion of the first body of the first gauge part is removed from the respective slot of the slot set, and moving the second gauge holder away from the stator so that the second body of the second gauge part is removed from the respective slot of the slot set.
In variations of the method of the above paragraph, which can be implemented individually or in any combination: the abrasive portion includes one or more of a series of ridges and a removable sandpaper structure and the method further includes moving the first gauge part in a reciprocating motion when the abrasive portion of the first body is at least partially inserted into the respective slot of the slot set.
Further areas of applicability will become apparent from the description provided herein. It should be understood that the description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.
In order that the disclosure may be well understood, there will now be described various forms thereof, given by way of example, reference being made to the accompanying drawings, in which:
The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way.
DETAILED DESCRIPTIONThe following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses. It should be understood that throughout the drawings, corresponding reference numerals indicate like or corresponding parts and features.
Referring to
The electric machine 10 may be powered by a traction battery (not shown) in the vehicle. The traction battery may provide a high-voltage direct current (DC) output from one or more battery-cell arrays, sometimes referred to as battery-cell stacks, within the traction battery. An AC/DC converter (not shown) converts the high-voltage (DC) current from the traction batter to three-phase AC current. The battery-cell arrays may include one or more battery cells that convert stored chemical energy to electrical energy. The cells may include a housing, a positive electrode (cathode), and a negative electrode (anode). An electrolyte allows ions to move between the anode and cathode during discharge, and then return during recharge. Terminals allow current to flow out of the cells for use by the vehicle.
With reference to
As shown in
The stator 12 undergoes a manufacturing process in which insulation 23 covering at least part of the stator 12 is formed by a molding process. For example, the end face 26 of the stator core 16, including the back iron 19 and the teeth 21, may be coated by the insulation. Upon completion of the molding process, dimensions of the slots 24 are measured to provide for the slots 24 being within predetermined tolerance ranges. One or more gauges may be used to measure the dimensions of the slots 24. Furthermore, burrs 60 (
With reference to
The gauge set 104 is configured to be at least partially inserted into the slot set 110 of the stator 12 to deburr the slots 24 in the slot set 110 and optionally to measure the dimensions of the slots 24 in the slot set 110. The gauge set 104 includes one or more gauge parts 120. It should be understood that the number of gauge parts 120 in the gauge set 104 equal the number of slots 24 in the slot set 110. For example, if the slot set 110 includes ten slots 24 then the gauge set 104 includes ten gauge parts 120. It should also be understood that the number of slots 24 in the slot set 110 may be less than the total number of slots 24 of the stator 12. For example, the stator 12 may include twenty-four total slots 24 and the slot set 110 may include six slots 24. In this way, the gauge holder 102 inserts the gauge set 104 into the stator 12 four separate times in order to deburr (and optionally measure the dimensions of the slots 24) every slot 24 in the stator 12 as will be described in more detail below. It should also be understood that slots 24 of the slot set 110 may equal the total number of slots 24 of the stator 12. For example, the slot set 110 may include twenty-four slots 24. In this way, the gauge holder 102 inserts the gauge set 104 into the stator 12 one time in order to deburr (and optionally measure the dimensions of the slots 24) every slot 24 in the stator 12.
With reference to
In the example illustrated, the abrasive portion 122 is formed around the entire body 118 (i.e., the abrasive portion 122 is formed on each of the sides 120a, 120b, 120c, 120d of the body 118) and is configured to deburr a respective slot 24 of the stator 12. In some forms, the abrasive portion 122 is partially formed around the entire body 118 (i.e., the abrasive portion 122 is formed on one or more sides 120a, 120b, 120c, 120d of the body 118). In the example illustrated, the abrasive portion 122 is located at an end 127 of the body 118. In some forms, the abrasive portion 122 may located along a center portion of the body 118. In other forms, the body 118 may include a plurality of abrasive portions that are spaced apart from each other along the length of the body 118. The abrasive portion 122 includes one or more abrasive materials configured to deburr the respective slot 24 (i.e., polish and/or clean surfaces defining the respective slot 24). In one example, as shown in
With reference back to
Referring to
Each gauge part 120 is inserted all the way into the respective slot 24 with a force and stroke such that the tapered end 128 (and optionally, the abrasive portion 122) of each gauge part 120 reaches an end (not shown) of the respective slot 24 (the end of the respective slot 24 is opposite end 36 of respective slot 24 where the gauge part 120 is inserted). If the force needed to insert each gauge part 120 all the way into the respective slot 24 as described above is below a predetermined threshold, then the dimensions of the slots 24 are within a predetermined tolerance range. If the force needed to insert each gauge part 120 all the way into the respective slot 24 as described above exceeds a predetermined threshold, then the dimensions of the slots 24 may not be within the predetermined tolerance range.
At 412, the control algorithm, using the controller 106, instructs the robot arm 107 (
If the slot set 110 includes the total number of slots 24 of the stator 12 then the gauge holder 102 inserts the gauge set 104 into the stator 12 one time in order to deburr (and optionally measure) every slot 24 in the stator 12. If the number of slots 24 in the slot set 110 is less than the total number of slots 24 of the stator 12 then the controller 106 instructs the robot arm 107 to rotate the gauge holder 102 such that the gauge set 104 is inserted into a different slot set 110 to deburr (and optionally measure) the slot set 110. This process is repeated until every slot 24 of the stator 12 is deburred and optionally measured. For example, if the stator 12 includes forty-eight total slots 24 and the slot set 110 includes twelve slots 24, then the gauge holder 102 inserts the gauge set 104 into four different slot sets 110 in order to deburr (and optionally measure) every slot 24 in the stator 12. In an alternative form, not specifically shown, the stator 12 may be on a rotatable platform and the controller 106 may control the platform to rotate the stator 12 to deburr (and optionally measure) the next slot set 110. The deburring gauge system 100 of the present disclosure enhances the efficiency of deburring and optionally measuring the stator 12 of the electric machine 10. It should also be understood that sensors (not shown) located on the gauge parts 120 or associated with the robot arm 107 may measure force needed to insert gauge parts 120 all the way into the slots 24 of the stator 12.
With reference to
The first gauge set 504a is removably coupled to the first gauge holder 502a. A first robot arm 507a may be coupled to the first gauge holder 502a and may move the first gauge holder 502a in a first direction X1 toward the stator 12 so that the first gauge set 504a is at least partially inserted into a slot set 110 of the stator 12, and in a second direction X2 away from the stator 12 so that the first gauge set 504a is removed from the slot set 110 of the stator 12. The first robot arm 507a may also rotate the first gauge holder 502a in a first rotational direction Z1 and in a second rotational direction Z2 that is opposite the first rotational direction.
The first gauge set 504a is configured to be at least partially inserted into the slot set 110 of the stator 12 to deburr the slots 24 in the slot set 110. The first gauge set 504a includes one or more gauge parts 520a (one shown in
With reference back to
The second gauge set 504b is configured to be at least partially inserted into the slot set 110 of the stator 12 to measure the dimensions of the slots 24 in the slot set 110. The second gauge set 504b includes one or more gauge parts 520b (
With reference to
Referring to
At 612, the control algorithm, using the controller 506, instructs the first robot arm 507a to move the first gauge holder 502a in the second direction X2 away from the stator 12 so that each gauge part 520a is removed from the respective slot 24 of the slot set 110 of the stator 12. After the first gauge holder 502a is moved in the second direction X2 so that each gauge part 520a is removed from the respective slot 24 of the slot set 110, the debris is removed from the stator 12. That is, the debris may be removed from the stator 12 using suction or blowing the debris off to inhibit residuals from the deburring to interfere with subsequent steps such as measurement or winding insertion steps. At 616, the control algorithm, using the controller 506, instructs the second robot arm 507b to move the second gauge holder 502b in the first direction X1 toward the stator 12 so that the body 518b of each gauge part 520b is at least partially inserted into the respective slot 24 of the slot set 110 of the stator 12. Each gauge part 520b of the second gauge set 504b is inserted into the stator 12 after each gauge part 520a of the first gauge set 504a is removed from the stator 12.
Each gauge part 520b is inserted all the way into the respective slot 24 with a force such that the end 529 of each gauge part 520b reaches the end (not shown) of the respective slot 24. If the force needed to insert each gauge part 520b all the way into the respective slot 24 as described above is below a predetermined threshold, then the dimensions of the slots 24 are within a predetermined tolerance range. If the force needed to insert each gauge part 520b all the way into the respective slot 24 as described above exceeds a predetermined threshold, then the dimensions of the slots 24 may not be within the predetermined tolerance range. It should be understood that the force needed to insert each gauge part 520b all the way into the respective slot 24 may be less than the force needed to insert each gauge part 120 described above into the respective slot 24. That is, less force may be needed to insert gauge parts 520b into the slots 24 when the slots 24 are first deburred by a previous deburring step (i.e., step 608) compared to when the deburring and measuring is happening simultaneously as described above with regard to gauge parts 120 (i.e., step 408). It should also be understood that sensors (not shown) located on the gauge parts 520b or associated with the second robot arm 507b may measure force needed to insert gauge parts 520b all the way into the slots 24 of the stator 12.
At 620, the control algorithm, using the controller 506, instructs the second robot arm 507b to move the second gauge holder 502b in the second direction X2 away from the stator 12 so that each gauge part 520b is removed from the respective slot 24 of the slot set 110 of the stator. In the example illustrated, each gauge part 520a of the first gauge set 502a and each gauge part 520b of the second gauge set 502b are both inserted into the same end of the respective slot 24 of the slot set 110. In some forms, each gauge part 520a of the first gauge set 502a is inserted into one end of the respective slot 24 of the slot set 110 and each gauge part 520b of the second gauge set 502b is inserted into another end of the respective slot 24 of the slot set 110 that is opposite the end. Each gauge part 520b of the second gauge set 502b may be inserted into the other end of the respective slot 24 of the slot set 110 after the first gauge set 502a is removed from the slot set 110.
In another form, a deburring gauge system (not shown) may include one robot (not shown) which switches between a first gauge holder having a first gauge set coupled thereto and a second gauge holder having a second gauge set coupled thereto instead of each of the first and second gauge holders being coupled to a respective robot arm as described above.
Unless otherwise expressly indicated herein, all numerical values indicating mechanical/thermal properties, compositional percentages, dimensions and/or tolerances, or other characteristics are to be understood as modified by the word “about” or “approximately” in describing the scope of the present disclosure. This modification is desired for various reasons including industrial practice, material, manufacturing, and assembly tolerances, and testing capability.
As used herein, the phrase at least one of A, B, and C should be construed to mean a logical (A OR B OR C), using a non-exclusive logical OR, and should not be construed to mean “at least one of A, at least one of B, and at least one of C.”
In this application, the term “controller” and/or “module” may refer to, be part of, or include: an Application Specific Integrated Circuit (ASIC); a digital, analog, or mixed analog/digital discrete circuit; a digital, analog, or mixed analog/digital integrated circuit; a combinational logic circuit; a field programmable gate array (FPGA); a processor circuit (shared, dedicated, or group) that executes code; a memory circuit (shared, dedicated, or group) that stores code executed by the processor circuit; other suitable hardware components (e.g., op amp circuit integrator as part of the heat flux data module) that provide the described functionality; or a combination of some or all of the above, such as in a system-on-chip.
The term memory is a subset of the term computer-readable medium. The term computer-readable medium, as used herein, does not encompass transitory electrical or electromagnetic signals propagating through a medium (such as on a carrier wave); the term computer-readable medium may therefore be considered tangible and non-transitory. Non-limiting examples of a non-transitory, tangible computer-readable medium are nonvolatile memory circuits (such as a flash memory circuit, an erasable programmable read-only memory circuit, or a mask read-only circuit), volatile memory circuits (such as a static random access memory circuit or a dynamic random access memory circuit), magnetic storage media (such as an analog or digital magnetic tape or a hard disk drive), and optical storage media (such as a CD, a DVD, or a Blu-ray Disc).
The apparatuses and methods described in this application may be partially or fully implemented by a special purpose computer created by configuring a general-purpose computer to execute one or more particular functions embodied in computer programs. The functional blocks, flowchart components, and other elements described above serve as software specifications, which can be translated into the computer programs by the routine work of a skilled technician or programmer.
The description of the disclosure is merely exemplary in nature and, thus, variations that do not depart from the substance of the disclosure are intended to be within the scope of the disclosure. Such variations are not to be regarded as a departure from the spirit and scope of the disclosure.
Claims
1. A deburring gauge system for a stator, the deburring gauge system comprising:
- a gauge set configured to be at least partially inserted into a slot set of the stator, each first gauge part of the gauge set includes a first body having a first cross-sectional shape that corresponds to a second cross-sectional shape of a respective first slot of the slot set, the first body of each first gauge part includes an abrasive portion extending along a length of the first body;
- a gauge holder secured to the gauge set; and
- a controller in communication with the gauge holder and configured to: move the gauge holder in a first direction toward the stator so that the abrasive portion of the first body is at least partially inserted into the respective first slot of the slot set of the stator; and move the gauge holder in a second direction away from the stator so that the abrasive portion of the first body is removed from the respective first slot of the slot set of the stator.
2. The deburring gauge system of claim 1, wherein the abrasive portion includes a series of ridges or a removable sandpaper structure.
3. The deburring gauge system of claim 1, wherein the abrasive portion includes a series of ridges and a removable sandpaper structure.
4. The deburring gauge system of claim 1, wherein each first gauge part of the gauge set includes an end extending from the first body, and wherein the end is tapered in the first direction.
5. The deburring gauge system of claim 1, wherein the controller is configured to move the gauge set in a reciprocating motion when the abrasive portion of the first body is at least partially inserted into the respective first slot of the slot set of the stator.
6. The deburring gauge system of claim 1, wherein the first body further includes a non-abrasive portion extending along the length of the first body, and wherein the abrasive portion extends along the length of the first body a first distance and the non-abrasive portion extends along the length of the first body a second distance that is greater than the first distance.
7. The deburring gauge system of claim 1, wherein the first cross-sectional shape of each first gauge part of the gauge set is rectangular.
8. The deburring gauge system of claim 1, wherein the gauge set further includes second gauge parts secured to another gauge holder, each second gauge part configured to be inserted into the respective first slot of the slot set, each second gauge part includes a second body having a third cross-sectional shape that corresponds to the second cross-sectional shape of the respective first slot of the slot set.
9. The deburring gauge system of claim 8, wherein a length of the second body of each second gauge part is greater than the length of the first body of each first gauge part.
10. A deburring gauge system for a stator, the deburring gauge system comprising:
- a first gauge set configured to be at least partially inserted into a slot set of the stator, each first gauge part of the first gauge set includes a first body having a first cross-sectional shape that corresponds to a second cross-sectional shape of a respective slot of the slot set, the first body of each first gauge part includes an abrasive portion extending along a length of the first body;
- a second gauge set configured to be at least partially inserted into the slot set of the stator, each second gauge part of the second gauge set includes a second body having a third cross-sectional shape that corresponds to the second cross-sectional shape of the respective slot of the slot set;
- a first gauge holder secured to the first gauge set;
- a second gauge holder secured to the second gauge set; and
- a controller in communication with the first gauge holder and the second gauge holder, the controller configured to: move the first gauge holder toward the stator so that the abrasive portion of the first body of each first gauge part is at least partially inserted into the respective slot of the slot set; move the first gauge holder away from the stator so that the abrasive portion of the first body of each first gauge part is removed from the respective slot of the slot set; move the second gauge holder toward the stator so that the second body of each second gauge part is at least partially inserted into the respective slot of the slot set, the second gauge holder being moved toward the stator after the abrasive portion of the first body of each first gauge part is removed from the respective slot of the slot set; and move the second gauge holder away from the stator so that the second body of each second gauge part is removed from the respective slot of the slot set.
11. The deburring gauge system of claim 10, wherein the abrasive portion includes one or more of a series of ridges and a removable sandpaper structure.
12. The deburring gauge system of claim 10, wherein the first body of each first gauge part is inserted into a first end of the respective slot of the slot set and the second body of each second gauge part is inserted into a second end of the respective slot of the slot set that is opposite the first end.
13. The deburring gauge system of claim 10, wherein the first body of each first gauge part is inserted into an end of the respective slot of the slot set and the second body of each second gauge part is inserted into the end of the respective slot of the slot set.
14. The deburring gauge system of claim 10, wherein a length of the second body of each second gauge part is greater than the length of the first body of each first gauge part.
15. The deburring gauge system of claim 10, wherein the first body includes a non-abrasive portion extending along the length of the first body a first distance, and wherein the abrasive portion extends along the length of the first body a second distance, the first distance being greater than or equal to the second distance.
16. The deburring gauge system of claim 10, wherein each first gauge part of the first gauge set includes an end extending from the first body, and wherein the end is tapered.
17. The deburring gauge system of claim 10, wherein the controller is configured to move the first gauge set in a reciprocating motion when the abrasive portion of the first body is at least partially inserted into the respective slot of the slot set.
18. A method for deburring and measuring a slot set of a stator, the method comprising:
- moving a first gauge holder toward the stator so that an abrasive portion of a first body of a first gauge part secured to the first gauge holder is at least partially inserted into a respective slot of the slot set;
- moving the first gauge holder away from the stator so that the abrasive portion of the first body of the first gauge part is removed from the respective slot of the slot set;
- moving a second gauge holder toward the stator so that a second body of a second gauge part secured to the second gauge holder is at least partially inserted into the respective slot of the slot set, the second gauge holder being moved toward the stator after the abrasive portion of the first body of the first gauge part is removed from the respective slot of the slot set; and
- moving the second gauge holder away from the stator so that the second body of the second gauge part is removed from the respective slot of the slot set.
19. The method of claim 18, wherein the abrasive portion includes one or more of a series of ridges and a removable sandpaper structure.
20. The method of claim 18, further comprising moving the first gauge part in a reciprocating motion when the abrasive portion of the first body is at least partially inserted into the respective slot of the slot set.
Type: Application
Filed: Sep 8, 2023
Publication Date: Mar 13, 2025
Applicant: Ford Global Technologies, LLC (Dearborn, MI)
Inventors: Franco Leonardi (Dearborn Heights, MI), Michael W. Degner (Novi, MI)
Application Number: 18/463,537